Hearing protection devices, noise exposure sensors therefor, and sensor housings and associated methods for the same

ABSTRACT

Disclosed are hearing protection devices and housings for noise sensors for the same. Hearing protection devices can include an ear cup including an external casing partially defining an inner space, a noise sensor including a microphone electrically coupled to a printed circuit board, and a housing disposed in an aperture defined in the external casing. The housing can define an axial bore defining a noise sensor receiving portion and an acoustic communication portion. The inner space of the ear cup can be substantially airtight when the housing is sealably disposed at or proximate the aperture, the microphone is engaged within the noise sensor receiving portion of the housing, and the ear cup is worn securely about the wearer&#39;s ear. The noise sensor can be calibrated by removing a removable securing collar and slidably disposing a calibration tool into the axial bore without further disassembling the hearing protection device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This specification is based upon and claims the benefit of priority fromEuropean patent application number EP 19176573.4 filed on May 24, 2019,the entire contents of which are incorporated herein by reference.

BACKGROUND

In the field of hearing protection, hearing protection devices such asearmuffs are often used to protect a wearer's ears from excessive noiseexposure. Such hearing protection devices often provide a passive and/oractive noise dampening or noise cancellation effect for the wearer,often in an effort to reduce the total noise exposure for a wearer tobelow a regulated or suggested acute or chronic exposure limit. In suchdevices, one or more noise sensors can be placed in or about the hearingprotection device. However, such noise sensors are often susceptible todamage from exposure to dust and other contaminants, often measure noiseexposure in a manner that is not true to the wearer's actual exposure,are costly to manufacture, require significant space within the hearingdevice, and often cannot be calibrated reliably and/or withoutsubstantial disassembly of the hearing protection device. Throughapplied effort, ingenuity, and innovation, many of these identifiedproblems have been solved by developing solutions that are included inembodiments of the present disclosure, many examples of which aredescribed in detail herein.

SUMMARY

Apparatus, systems, and methods described herein relate to hearingprotection devices and noise exposure sensor housings for the same. Insome embodiments, the hearing protection device can include an ear cupincluding an external casing partially defining an inner space, a noisesensor including a microphone electrically coupled to a printed circuitboard, and a housing disposed in an aperture defined in the externalcasing. The housing can define an axial bore defining a noise sensorreceiving portion and an acoustic communication portion. The inner spaceof the ear cup can be substantially airtight when the housing issealably disposed at or proximate the aperture, the microphone isengaged within the noise sensor receiving portion of the housing, andthe ear cup is worn securely about the wearer's ear. The noise sensorcan be calibrated by removing a removable securing collar and slidablydisposing a calibration tool into the axial bore without furtherdisassembling the hearing protection device.

In some embodiments, a noise sensor assembly for a hearing protectiondevice can include a noise sensor comprising a microphone electricallycoupled to a printed circuit board (PCB). In some embodiments, the noisesensor assembly can comprise a housing dimensioned and configured to befixably disposed at or proximate an aperture defined in an outer surfaceof an external casing of the hearing protection device. In someembodiments, the housing can comprise an inner surface defining an axialbore. In some embodiments, a distal end of the axial bore is configuredto acoustically communicate with an external environment via theaperture. In some embodiments, the housing can define a noise sensorreceiving portion comprising a slot configured to engage the PCB of thenoise sensor. In some embodiments, the slot of the housing is configuredto retain the noise sensor, such that the microphone faces the axialbore. In some embodiments, in an instance in which the noise sensor isengaged with the housing, the noise sensor is sealed against thehousing. In some embodiments, the axial bore of the housing isdimensioned and configured to slideably receive a calibration tool toform an airtight seal with the inner surface of the housing. In someembodiments, the housing can further define a securing portion at adistal end, the securing portion adapted to contact and secure thehousing with respect to a portion of the outer surface of the hearingprotection device. In some embodiments, the noise sensor assembly canfurther comprise an internal dust protector disposed between the noisesensor receiving portion of the housing and the noise sensor, andwherein the internal dust protector is disposed between the microphoneand the axial bore. In some embodiments, the housing comprises at leastone of a vibration attenuation material and a noise dampening material.In some embodiments, in an instance in which the noise sensor is engagedwith the housing, the noise sensor is retained within the noise sensorreceiving portion and abuts the slot.

In some embodiments, an ear cup for a hearing protection device isdisclosed. In some embodiments, the hearing protection device cancomprise an external casing defining an aperture. In some embodiments,the ear cup can comprise a noise sensor comprising a microphoneelectrically coupled to a printed circuit board (PCB) and a housingfixably disposed at or proximate the aperture defined by the externalcasing. In some embodiments, the housing can comprises an inner surfacedefining an axial bore. In some embodiments, a distal end of the axialbore is configured to acoustically communicate with an externalenvironment via the aperture. In some embodiments, the housing defines anoise sensor receiving portion comprising a slot configured to engagethe PCB of the noise sensor. In some embodiments, the slot of thehousing is configured to retain the noise sensor, such that themicrophone faces the axial bore. In some embodiments, in an instance inwhich the noise sensor is engaged with the housing, the noise sensor issealed against the housing, and the noise sensor and the housing sealthe aperture defined by the external casing. In some embodiments, theear cup can further comprise a removable securing collar. In someembodiments, the external casing comprises a first portion and a secondportion, the second portion defining the aperture configured to sealablyretain the removable securing collar, the second portion configured tosealably engage the first portion such that the first portion, thesecond portion, and the removable securing collar seal the aperture inthe external casing. In some embodiments, the noise sensor receivingportion of the axial bore has a first inner diameter and the distal endportion of the axial bore has a second inner diameter less than thefirst inner diameter. In some embodiments, the ear cup can furthercomprise a removable sealing collar configured to sealably retain thehousing at or proximate the aperture defined by the external casing, theremovable securing collar comprising an opening such that the distal endof the axial bore of the housing is configured to acousticallycommunicate with the external environment via the aperture of theexternal casing and the opening of the removable sealing collar. In someembodiments, the ear cup can further comprise a removable sealing collarconfigured to be retained by the aperture, wherein the axial bore of thehousing is configured such that when the removable securing collar isremoved and the calibration tool is slideably inserted into the axialbore of the housing, the calibration tool forms an airtight seal with aninner surface of the axial bore of the housing. In some embodiments, theear cup can further comprise an external dust protector disposed betweenthe housing and the removable securing collar. In some embodiments, thehousing further comprises a securing portion disposed about the axialbore, the securing portion comprising a first securing portion at adistal end of the housing having a first outer diameter and a secondsecuring portion proximal of the first securing portion, the secondsecuring portion have a second outer diameter less than the first outerdiameter, the first securing portion and the second securing portiondefining a flange and recess configured to secure the housing relativeto the external casing. In some embodiments, in an instance in which thenoise sensor is engaged with the housing and the housing is sealablydisposed directly or indirectly at or proximate the aperture of theexternal casing of the ear cup, and the ear cup is sealably engaged to awearer's head about the wearer's ear, an internal volume of the ear cupis substantially airtight.

In some embodiments, a method for calibrating a noise sensor of ahearing protection device is described. In some embodiments, the hearingprotection device can comprise an external casing defining an aperture,a noise sensor comprising a microphone electrically coupled to a printedcircuit board (PCB) and a housing fixably disposed at or proximate theaperture defined by the external casing. In some embodiments, thehousing of the hearing protection device can comprises an inner surfacedefining an axial bore. In some embodiments, a distal end of the axialbore of the housing of the hearing protection device can be configuredto acoustically communicate with an external environment via theaperture. In some embodiments, the housing of the hearing protectiondevice can define a noise sensor receiving portion comprising a slotconfigured to engage the PCB of the noise sensor. In some embodiments,the slot of the housing of the hearing protection device can beconfigured to retain the noise sensor, such that the microphone facesthe axial bore. In some embodiments, in an instance in which the noisesensor is engaged with the housing of the hearing protection device, thenoise sensor can be sealed against the housing and the noise sensor andthe housing can seal the aperture defined by the external casing of theear cup. In some embodiments, the ear cup can further comprise aremovable securing collar configured to retain the noise sensor and/orthe housing in place in or proximate the aperture. In some embodiments,the method can comprise at least disposing a calibration tool throughthe aperture via the axial bore of the housing such that an interior ofthe calibration tool and the microphone are part of a closed system. Insome embodiments, the method can comprise emitting, by the calibrationtool, a calibrating sound having predetermined sound characteristics. Insome embodiments, the method can comprise receiving, using themicrophone, one or more detected sound characteristics of thecalibrating sound. In some embodiments, in an instance in which acomparison of the one or more detected sound characteristics of thecalibrating sound received by the microphone and the soundcharacteristics of the calibrating sound is indicative of a calibrationerror, calibrating the noise sensor relative to the calibrating sound.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which constitute a part of the description,illustrate embodiments of the present invention and, together with thedescription thereof, serve to explain the principles of the presentinvention.

FIG. 1A shows a perspective view of a hearing protection device,according to an embodiment of the present invention.

FIG. 1B shows a cut-away view of the hearing protection device of FIG.1A, according to an embodiment of the present invention.

FIG. 1C shows a detail from the cut-away view of the hearing protectiondevice shown in FIG. 1B, according to an embodiment of the presentinvention.

FIG. 1D illustrates an approach for calibrating a noise sensor for thehearing protection device shown in FIG. 1B, according to an embodimentof the present invention.

FIGS. 2A-2E show various views of a housing for noise sensor of ahearing protection device, according to an embodiment of the presentinvention.

FIGS. 3A and 3B show various views of a noise sensor for a hearingprotection device, according to an embodiment of the present invention.

DETAILED DESCRIPTION

It should be understood that although illustrative implementations ofone or more embodiments are disclosed and discussed below, the disclosedsystems and methods may be implemented using any number of techniques,whether currently known or not yet in existence. The disclosure shouldin no way be limited to the illustrative implementations, drawings, andtechniques illustrated below, but may be modified within the scope ofthe appended claims along with their full scope of equivalents. Thefollowing description of at least one exemplary embodiment is in factmerely illustrative and is in no way intended as a limitation to thepresent invention and its application or use.

Techniques and devices known to those of ordinary skill in the relevantart may not be discussed in detail but where appropriate, the techniquesand devices should be considered as part of the description. Among allthe examples shown and discussed herein, any specific value should beconstrued as merely illustrative and not as a limitation. Thus, otherexamples of exemplary embodiments may have different values. It shouldbe noted that similar reference numerals and letters denote similaritems in the accompanying drawings, and therefore, once an item isdefined in a drawing, there is no need for further discussion in theaccompanying drawings.

The following brief definition of terms shall apply throughout theapplication:

The term “comprising” means including but not limited to, and should beinterpreted in the manner it is typically used in the patent context;

The phrases “in some embodiments,” “in one embodiment,” “according toone embodiment,” and the like generally mean that the particularfeature, structure, or characteristic following the phrase may beincluded in at least one embodiment of the present invention, and may beincluded in more than one embodiment of the present invention(importantly, such phrases do not necessarily refer to the sameembodiment);

If the specification describes something as “exemplary” or an “example,”it should be understood that refers to a non-exclusive example;

The terms “about” or “approximately” or the like, when used with anumber, may mean that specific number, or alternatively, a range inproximity to the specific number, as understood by persons of skill inthe art field; and

If the specification states a component or feature “may,” “can,”“could,” “should,” “would,” “preferably,” “possibly,” “typically,”“optionally,” “for example,” “often,” or “might” (or other suchlanguage) be included or have a characteristic, that particularcomponent or feature is not required to be included or to have thecharacteristic. Such component or feature may be optionally included insome embodiments, or it may be excluded.

In the field of hearing protection, hearing protection devices such asearmuffs may be used to protect a wearer's ears from excessive noiseexposure. Such hearing protection devices may provide a passive and/oractive noise dampening or noise cancellation effect for the wearer,often in an effort to reduce the total noise exposure for a wearer tobelow a regulated or suggested acute or chronic exposure limit. Forinstance, an 8 hour maximum daily exposure time may be associated with anoise exposure level of about 85 decibels (dBA), while a person may belimited to 2 hours of exposure time per day for a noise exposure levelof 91 dBA, 30 minutes for a noise exposure level of 97 dBA, and sevenminutes for a noise exposure level of 103 dBA. By wearing such hearingprotection devices, a wearer is able to reduce their noise exposurelevel, thereby lengthening the maximum daily exposure time such that thewearer can, for example, remain in a higher ambient noise workingenvironment for a longer period of time under such exposure limitregulations. In some embodiments discussed herein, to perform activenoise cancellation and/or verify that the hearing protection device iseffectively preventing noise exposure during use, one or more noisesensors can be placed in or about the hearing protection device (e.g.,on or in an ear cup of a pair of earmuffs). Since these noise sensorsmust be quite small while also being effective, microelectro-mechanicalsystem (MEMS) microphones can be used as the noise sensors. Embodimentsof the present disclosure facilitate such noise sensors, and may reduceexposure to dust and other contaminants, may measure noise exposure in amanner that is true to the wearer's actual exposure, and may becalibrated reliably and/or without substantial disassembly of thehearing protection device while having a small footprint in the hearingprotection device and being cost effective.

Microphones, such as MEMS microphones, for use as a noise exposuresensor in ear muffs or other such hearing protection can often comprisea vibrating diaphragm and a back electrode, forming a capacitorintegrated on a silicon wafer, which thereby realizes theacoustic-electric conversion. Such a capacitive microphone may beprovided with through holes on its back electrode in order to balancethe pressure between the vibrating diaphragm and the back electrode. Themicrophone of such a structure, especially when the cavity about themicrophone is sealed and filled with air, has higher acoustic impedancecompared to the traditional microphone, and thereby has higher noiseattenuation. Since a sealed, air-filled cavity about the microphone canbe an important factor in achieving accurate detection of a calibratingnoise during in situ calibration, such calibration of the noise sensormicrophone and/or a printed circuit board thereof, especially in smalland/or complex electronic equipment such as hearing protection devices,may be difficult or impossible for conventional hearing protectiondevices without significant disassembly of the hearing protectiondevice, or may be completely impossible.

Systems, apparatuses, and methods disclosed herein generally relate tohearing protection devices and noise exposure sensor housings for thesame. In some embodiments, a system can include an ear cup for a hearingprotection device that defines an aperture on an exterior casing orother such surface. In some embodiments, the ear cup can further includea housing fixably disposed at or proximate the aperture and defining anaxial bore therethrough. In some embodiments, the housing can have aproximal portion of the axial bore that is defined in part by a slot orledge such that the proximal portion is configured to receive amicrophone or other such sensor. In some embodiments, the housing canhave a distal portion of the axial bore having an inner diameter that isless than the inner diameter of the proximal portion. In someembodiments, the ledge can be defined by the portion of the axial boreat the transition between the narrower distal portion and the widerproximal portion. In some embodiments, the ledge can be formed as asurface facing the proximal end of the housing. In some embodiments, theproximal portion of the axial bore can have a wider inner diameter atthe transition point from the distal portion to the proximal portion,the transition point defining the ledge. In some embodiments, the innerdiameter of the proximal portion can be smaller at one or more pointsproximal the transition point such that the slot is formed. In someembodiments, the slot can be the portion of the proximal portion or ofthe axial bore in general that has the largest inner diameter such thatthe noise sensor can be retained in that portion against axial movementby a reduced inner diameter both distal the slot and proximal the slot.In some embodiments, a narrower region of the proximal portion of theaxial bore proximal the slot can be at least partially open in a radialdirection, meaning a region of an outer wall of the housing aligned withthe narrower region of the proximal portion can extend only part of theway around the axial bore, such that one or more components of the noisesensor can extend out radially from the proximal portion of the axialbore at a location proximal the slot. In some embodiments, the distalportion can be configured to receive ambient noise from the environmentoutside the ear cup and communicate that ambient noise to the microphoneor other such sensor disposed and retained within the proximal portion(also known herein as the noise sensor receiving portion) of thehousing. In some embodiments, the microphone or other such sensordisposed within the proximal portion of the housing can be connected toone or more printed circuit boards (PCB) having a somewhat planarstructure or any other suitable form factor. In some embodiments, someor all of one or more PCBs may be flexible. In some embodiments, the oneor more PCBs can include a microphone PCB operably coupled to themicrophone or other such sensor and a flexible PCB operably connected tothe microphone PCB.

In some embodiments, the ear cup can further include an internal dustprotector disposed between the microphone and the housing at theproximal end of the distal portion of the axial bore such that themicrophone can be exposed to ambient noise communicated through thedistal portion of the axial bore without being exposed or with onlyslight exposure to contaminants such as dust from the environmentoutside the ear cup. In some embodiments, the ear cup can furtherinclude a removable securing collar disposed on and/or at or proximatethe aperture of the external casing of the ear cup in such a way as tosecure the housing at or proximate the aperture. In some embodiments,the removable securing collar can define an opening through a portion,such as the center, of the removable securing collar. In such a way, insome embodiments, the ambient noise from the environment outside the earcup can be freely communicated through the opening of the removablesecuring collar, into the distal portion of the axial bore, and to themicrophone or other such noise sensor assembly disposed within theproximal portion of the axial bore of the housing. In some embodiments,the ear cup can further include an external dust protector disposedwithin, on, or about the aperture of the external casing of the ear cup,between the distal end of the housing and the removable securing collar.In some embodiments, the internal dust protector and the external dustprotector can together prevent contaminants such as dust and otherdebris common to construction sites and other similar environments fromreaching the microphone and other electronics and circuitry within theear cup.

In some embodiments, the ear cup can further include an ear paddimensioned and configured to be sealably disposed to a wearer's headabout a wearer's ears. In some embodiments, the ear pad can include orbe made from a cushioning material, such as a deformable foam or rubbermaterial such that ear pad has a noise dampening effect for the wearerwhen properly wearing the hearing protection device. In someembodiments, in addition to enclosing the wearer's ear within the earcup and providing comfort, the ear pad can serve a similar purpose asthe internal dust protector and/or the external dust protector, which isto at least reduce and possibly prevent the communication of dust andother contaminants into the ear cup, when properly worn by the wearer.In some embodiments, therefore, an interior space defined within the earcup by at least the ear pad, the external casing of the ear cup, thehousing disposed at or proximate the aperture of the external casing,and the microphone or other such sensor disposed within the proximalportion of the axial bore of the housing can be airtight orsubstantially airtight when properly worn by the wearer.

In some embodiments, the distal portion of the axial bore of the housingcan be configured and dimensioned such that a noise sensor calibrationtool can be securely inserted within the axial bore and sealed againstthe axial bore for microphone calibration by removing the removablesecuring collar, removing the external dust protector, and slideablydisposing the noise sensor calibration tool into the axial bore via adistal opening of the axial bore. In some embodiments, securely engagingthe noise sensor calibration tool within the axial bore for calibrationof the microphone or other such noise sensor can ensure that ambientnoise from the environment outside the ear cup is not detected by themicrophone during calibration and that a calibrating noise emitted bythe noise sensor calibration tool during in situ calibration of themicrophone or other such noise sensor remains substantially within theaxial bore and is not emitted to the interior space of the ear cup orthe environment outside the ear cup. As such, in some embodiments, themicrophone or other such noise sensor can be calibrated in place withoutsignificant disassembly of the hearing protection device and such thatthe space around the microphone is substantially airtight duringcalibration, increasing the accuracy of calibration.

In some embodiments, the housing may include a securing portion at thedistal end of the housing that has a narrower portion relative to theouter diameter of the main body of the housing proximal the narrowerportion and a wider portion distal the narrower portion. The securingportion, in combination with the remaining structure of the housing andcasing, may ensure that the ear cup is airtight during operation. Insome embodiments, an outer diameter of the narrower portion isdimensioned and configured to correspond substantially with an innerdiameter of the aperture of the external casing of the ear cup or anintermediate component such as a contacting lip disposed proximate theaperture such that the housing can be inserted into the aperture andretained sealably in place when an outer surface of the narrower portionof the housing abuts an inner surface or an inner edge of the aperture.In some embodiments, the housing can be disposed within the ear cupwithout necessarily engaging the external casing of the ear cup. In someembodiments, the housing can be at least somewhat deformable such thatthe wider portion of the housing can be fit through the aperture of theexternal casing of the ear cup during assembly of the ear cup. In someembodiments, the ear cup can be assembled, at least in part, bytemporarily deforming the wider portion at or near the distal end of thehousing and fitting the wider portion through the aperture from theinside of the external casing of the ear cup, soldering or otherwiseelectrically coupling the microphone to the PCB, and disposing themicrophone through an opening at the proximal end of the housing untilthe microphone comes to rest on the ledge or slot defined at atransition point where the proximal portion of the axial bore narrows todefine a proximal end of the distal portion of the axial bore. In someembodiments, the housing can be a monolithic structure in order tofacilitate the airtight nature of the interior region of the ear cupduring use of the hearing protection device and the airtight nature ofthe axial bore during calibration of the microphone.

FIG. 1A-1D show a hearing protection device 10 according to anembodiment described herein. The hearing protection device 10 asillustrated in FIG. 1A includes a supporting band 105 connecting a firstear cup 100 a to a second ear cup 100 b. An ear cup 100 a,b can comprisea structural cup lined with sound-dampening material (also known hereinas an “ear pad”) dimensioned and configured to engage a wearer's headabout the wearer's ears such that the sound-dampening material sealablyengages the wearer's head. As such, when properly worn, the hearingprotection device 10 can be configured to prevent at least some of theambient noise to which the wearer would otherwise be exposed if notwearing the hearing protection device 10 from reaching the wearer'sears. In some embodiments, each of the ear cups 100 a,b of the hearingprotection device 10 can further include a noise sensor assembly 110a,b. The first ear cup 110 a and the second ear cup 100 b can be similarto, a mirror image configurationally of, dissimilar to, or identical toone another. As such, the ear cups 100 a,b are hereinafter referredgenerally as an ear cup 100 and components thereof will be referred toas a noise sensor assembly 110, a removable securing collar 111, and thelike, without identifying a particular ear cup.

In some embodiments, the noise sensor assembly 110 can be positionedanywhere on or near the external surface of the ear cup 100 such thatambient noise from nearby the wearer's ear, external to the ear cups canbe measured using the noise sensor assembly 110. This noise exposuresignal can then be used in active noise cancellation to generate adestructively interfering audio signal that is generated via a processorand memory in one or both ear cups (e.g., on the main PCB of the earcups) and output via the speakers shown in each ear cup. The noiseexposure signal may additionally or alternatively be used to comparewith a noise exposure signal from a microphone inside the ear cups todetermine the drop in noise exposure between the exterior and interiorof the ear cups (e.g., to confirm that the hearing protection device isworking properly and is properly sealed and worn on the user's head). Insome embodiments, the noise sensor assembly 110 can be positioned asclose to the wearer's ear as possible, such as on an outer portion ofthe ear cup 100 near the sound-dampening material. Without wishing to bebound by any particular theory, placing the noise sensor assembly 110 onor in the ear cup 100 at a position sufficiently nearby the wearer's earmay increase the accuracy of the sensed noise relative to actual noiseto which the wearer would be exposed were they not wearing the hearingprotection device 10. In some embodiments, the hearing protection device10 can further include a removable securing collar 111 disposed aboutthe noise sensor assembly 110 and configured to retain the noise sensorassembly 110 at or proximate an aperture of the ear cup 100.

In some embodiments, the removable securing collar 111 can be disposedto an outer surface of the hearing protection device 10 and can beconfigured to span an aperture defined through the outer surface of thehearing protection device 10. In some embodiments, the removablesecuring collar 111 can be configured to the noise sensor assembly 110on, within, or partially within the hearing protection device 10. Insome embodiments, the removable securing collar 111 can include anopening dimensioned and configured to transmit sound therethrough to thenoise sensor assembly 110. In some embodiments, the hearing protectiondevice 10 can further include an external dust protector disposedbetween the noise sensor assembly 110 and the removable securing collar111.

As illustrated in FIGS. 1B and 1C, the ear cup 100 can further include anoise sensor assembly 110 comprising a housing 116 (e.g., 116 a, 116 b)fixably disposed at or proximate the aperture and defining an axial bore123 a, 123 b therethrough. In some embodiments, the housing 116 can havea proximal portion of the axial bore 123 a, 123 b that is defined inpart by a slot or ledge (not shown) such that the proximal portion isconfigured to receive a microphone 118 or other such sensor. In someembodiments, the housing 116 can have a distal portion of the axial bore123 a, 123 b having an inner diameter that is less than the innerdiameter of the proximal portion. In some embodiments, the distalportion of the housing 116 can be configured to receive ambient noisefrom the environment outside the ear cup 100 and communicate thatambient noise to the microphone 118 or other such sensor disposed andretained within the proximal portion (also known herein as a noisesensor receiving portion 125) of the housing 116. In some embodiments,the microphone 118 or other such sensor disposed within the proximalportion of the housing 116 can be disposed on one of the sensor printedcircuit boards 114 a, 114 d (sensor PCBs 114 a, 114 d) and may beconnected to one or more flexible printed circuit boards 114 b, 114 e(flexible PCB 114 b, 114 e). In some embodiments, the one or moreflexible PCBs 114 b, 114 e can be operably coupled to one or more mainPCBs 114 c, 114 f.

In some embodiments, the noise sensor assembly 110 can further includean internal dust protector 119 disposed between the microphone 118 andthe housing 116 at the proximal end of the distal portion of the axialbore 123 a, 123 b (e.g., disposed between the sensor PCB 114 a or 114 dand the ledge) such that the microphone 118 can be exposed to ambientnoise communicated through the distal portion of the axial bore 123 a,123 b of the housing 116 without being exposed or with only slightexposure to contaminants such as dust from the environment outside theear cup 100.

In some embodiments, the ear cup 100 can further include the removablesecuring collar 111 disposed at or proximate the aperture definedthrough one or more components of a casing of the ear cup 100 in such away as to secure the noise sensor assembly 110 within the ear cup 100and as a way to access the noise sensor assembly 110 withoutdisassembling the whole ear cup 100. The casing can comprise one or moreof a first external casing portion 117, a second external casing portion121, an insert catch 115 coupled to one or more of the first externalcasing portions 117, 121, and a contacting lip 112 coupled to the insertcatch 115. Herein, the term “external casing” or “external casing 117”is used to refer to any one or any combination of these or similarelements configured to define or partly define the aperture throughwhich the microphone 118 can be in acoustic communication with theenvironment outside the ear cup 100. In some embodiments, the hearingprotection device 10 may be assembled at least in part by gluing orotherwise permanently adhering the ear pad 120 a,b to the inside of theear cup 100 a,b, which can make it difficult to access the noise sensorassembly 110 by way of an inner surface 122 a,b of the ear cup 100 a,b.Likewise, the durability and air tightness of the ear cup 100 may becompromised if the ear cup 100 is opened along manufacturing lines,e.g., at a seam formed between the first and second portions of theexternal casing 117, 121 of the ear cup 100.

In some embodiments, the removable securing collar 111 can define anopening through a portion, such as the center, of the removable securingcollar 111, by which the noise sensor assembly 110 can be accessedwithout significant disassembly of the ear cup 100 and withoutcompromising the hearing protection characteristics of the hearingprotection device 10. In some embodiments, the removable sealing collar111 can further engage with the inset catch 115 of the external casing117. The external casing 117 may be configured to carry or define thecontacting lip 112 either as an integral piece or a separately insertedelement. In some embodiments, the distal end of the housing 116 can beconfigured to rest on one or both of the inset catch 115 or thecontacting lip 112 such that the removable securing collar 111 or aportion thereof can be fixedly inserted between the external dustprotector 113 and the inset catch 115. As such, the external surface ofthe removable securing collar 111 can be flush or substantially flushwith the outside surface of the external casing 117 of the ear cup 100.

In such a way, in some embodiments, the ambient noise from theenvironment outside the ear cup 100 can communicate through the openingof the removable securing collar 111, into the distal portion of theaxial bore 123, and to the microphone 118 or other such noise sensordisposed within the proximal portion of the axial bore 123 of thehousing 116. In some embodiments, the ear cup 100 can further include anexternal dust protector 113 disposed within, on, or about the apertureof the external casing 117 of the ear cup 100, between the distal end ofthe housing 116 and the removable securing collar 111. In someembodiments, the internal dust protector 119 and/or the external dustprotector 113 can prevent contaminants such as dust and other debriscommon to construction sites and other similar environments fromreaching the microphone 118 and other electronics and circuitry withinthe ear cup 100 while also preventing the axial bore 123 from becomingclogged and impairing the performance of the microphone 118.

In some embodiments, the ear cups 100 a,b can further include ear pads120 a,b dimensioned and configured to be sealably disposed to a wearer'shead about a wearer's ear. In some embodiments, the ear pad 120 caninclude or be made from a cushioning material, such as a deformable foamor rubber material such that the ear pad 120 has a noise dampeningeffect for the wearer when properly wearing the hearing protectiondevice 10. In some embodiments, the ear pad 120 can serve a similarpurpose as the internal dust protector 119 and/or the external dustprotector 113, which is to at least reduce and possibly prevent thecommunication of dust and other contaminants into the ear cup 100, whenproperly worn by the wearer. In some embodiments, therefore, an interiorspace, defined within the ear cup 100 by at least the ear pad 120, theexternal casing 117 of the ear cup 100, the housing 116 disposed at orproximate the aperture of the external casing 117 of the ear cup 100,and the microphone 118, sensor PCB 114 a, or other such sensor elementdisposed within the proximal portion of the axial bore 123 of thehousing 116, can be airtight or substantially airtight when properlyworn by the wearer to provide effective noise reduction for the wearer.

As illustrated in FIG. 1D, the distal portion of the axial bore 123 ofthe housing 116 can be configured and dimensioned such that a noisesensor calibration tool 150 comprising a calibration tube 151 can besecurely fixed within the axial bore 123 for microphone 118 calibrationby removing the removable securing collar 111, removing the externaldust protector 113, and slideably disposing the noise sensor calibrationtool 150 into the axial bore 123 via a distal opening of the axial bore123 of the housing 116. In some embodiments, securely fixing the noisesensor calibration tool 150 or the calibration tube 151 within the axialbore 123 of the housing 116 for calibration of the microphone 118 orother such noise sensor can help prevent or reduce ambient noise fromthe environment outside the ear cup 100 being detected by the microphone118 during calibration and that a calibrating noise emitted by the noisesensor calibration tool during in situ calibration of the microphone 118or other such noise sensor remains substantially within the axial bore123 of the housing 116 and is not emitted to the interior space of theear cup 100 or the environment outside the ear cup 100. As such, in someembodiments, the microphone 118 or other such noise sensor can becalibrated in place without significant disassembly of the hearingprotection device 10 and such that the space around the microphone 118is substantially airtight during calibration, increasing the accuracy ofcalibration. For example, in some embodiments, the external dustprotector 113 may be removed for calibration, while the internal dustprotector 119 is left in place.

In some embodiments, such as when a hearing protection system andassociated apparatus benefit from being airtight, during use and/orduring calibration, it was found to be helpful to dimension andconfigure the housing 116 to have or define a securing portion at thedistal end of the housing 116 that has a narrower portion relative tothe outer diameter of the main body of the housing 116 proximal thenarrower portion of the housing 116 and a wider portion of the housing116 distal the narrower portion of the housing 116. In some embodiments,an outer diameter of the narrower portion of the housing 116 can bedimensioned and configured to correspond substantially with an innerdiameter of the aperture of the external casing 117 of the ear cup 100(or as applicable, a narrower opening in the external casing, such asthe contacting lip 112 shown in FIG. 1C) such that the housing 116 canbe inserted into the aperture of the external casing 117 and retainedsealably in place when an outer surface of the narrower portion of thehousing 116 abuts an inner surface or an inner edge at or proximateaperture of the external casing 117 to at least partially seal theaperture. In some embodiments, the housing 116 can be at least somewhatdeformable such that the wider portion of the housing 116 can be fitthrough the aperture of the external casing 117 of the ear cup 100during assembly of the ear cup. In some embodiments, the ear cup 100 canbe assembled, at least in part, by temporarily deforming the widerportion of the housing 116 at or near the distal end of the housing 116and fitting the wider portion of the housing 116 through the aperture ofthe external casing 117 of the ear cup 100 from the inside of the earcup 100, soldering or otherwise electrically coupling the microphone 118to the sensor PCB 114 a, and disposing the microphone 118 through anopening at the proximal end of the housing 116 until the sensor PCB 114a comes to rest on the ledge or slot defined at a transition point wherethe proximal portion of the axial bore 123 of the housing 116 narrows todefine a proximal end of the distal portion of the axial bore 123. Insome embodiments, the housing 116 can be a monolithic structure in orderto facilitate the airtight nature of the interior region of the ear cup100 during use of the hearing protection device 10 and the airtightnature of the axial bore 123 of the housing 116 during calibration ofthe microphone 118.

In some embodiments, the external casing 117 of the hearing protectiondevice 10 can include a first portion 121 and a second portion 124. Insome embodiments, the first portion 121 and/or the second portion 124can be configured to at least partially define the aperture. In someembodiments, the external casing 117 can be configured to sealablyretain the removable securing collar 111 in the aperture. In someembodiments, the second portion 124 of the external casing 117 can beconfigured to be sealed to the first portion 121 such that at least aportion of the first portion 121 of the external casing 117, the secondportion 124 of the external casing 117, the removable securing collar111, the ear pad 120, and/or the housing 116 define the inner space ofthe ear cup 110 of the hearing protection device 10.

In some embodiments, the housing 116 can comprise an inner surfacedefining an axial bore 123. In some embodiments, a distal end of theaxial bore 123 of the housing 116 can be configured to acousticallycommunicate with an external environment via the aperture defined in theexternal casing 117. In some embodiments, the housing 116 can define anoise sensor receiving portion 125 comprising a slot 116 r, a ridge 116u, and/or a ledge 116 k configured to engage at least a portion of thenoise sensor assembly 110, such as the sensor PCB 114 a and/or themicrophone 118. In some embodiments, the proximal portion of the axialbore 123 can comprise or define the noise sensor receiving portion 125.In some embodiments, the noise sensor receiving portion 125 can bedefined as a portion of the axial bore 123 between the proximal portionand the distal portion. In some embodiments, the slot 116 r of thehousing 116 can be configured to retain the noise sensor 110, such thatthe microphone 118 is configured to receive acoustic signals from theaxial bore 123, e.g., the distal end of the axial bore 123. In someembodiments, in an instance in which the sensor PCB 114 a is engagedwith the housing 116, the sensor PCB 114 a can be sealed against thehousing 116 and the sensor PCB 114 a and the housing 116 seal theaperture defined by the external casing 117 of the ear cup 100. In otherwords, in some embodiments, the housing 116 can be secured at orproximate the aperture of the external casing 117 and the microphone 118and sensor PCB 114 a can be secured within the noise sensor receivingportion 125 of the housing 116 such that ambient noise from outside theear cup 100 can reach the microphone 118 by way of the axial bore 123defined by the housing 116.

In some embodiments, the ear cup 100 can further include an interiorregion defined at least in part by the exterior casing 117 of the earcup 100 and an ear pad 120 configured to contact a wearer's head aboutthe wearer's ear. In some embodiments, the housing 116, in conjunctionwith the microphone 118 and the ear pad 120, can be configured such thatthe interior region of the ear cup 110 can be airtight or substantiallyair tight when the wearer is wearing the hearing protection device. Insome embodiments, the ear cup 110 can further include a removablesecuring collar 111 configured to secure the housing 116 in place at orproximate the aperture of the external casing 117. In some embodiments,the removable securing collar 111 can define an opening through themiddle or substantially through the middle of the removable securingcollar 111 such that ambient noise can travel through the opening of theremovable securing collar 111, into the axial bore 123 of the housing116, and reach the microphone 118. In some embodiments, the ear cup 110can further include an external dust protector 113 disposed between thedistal end of the housing 116 and the removable securing collar 111. Insome embodiments, the external dust protector 113 can be configured toimpede the communication of debris such as dust, dirt, moisture, and thelike into the housing 116 without impeding the audible communication ofambient noise to the microphone 118 during use of the hearing protectiondevice.

In some embodiments, the removable securing collar 111 and/or externaldust protector 113 can be removed in order to access the axial bore 123for in situ calibration of the microphone 118. In other words, byremoving the removable securing collar 111, the calibration tool 150have a sufficient form factor can be slideably inserted into the axialbore 123 of the housing 116 such that a calibrating sounds can beemitted nearby the microphone 118. In some embodiments, the removablesecuring collar 111 may be engaged with the external casing 117 via oneor more securing tabs or other interference fit structures, such thatadhesives and permanent affixation elements are not required. In someembodiments, it can be helpful or even necessary to form an airtight orsubstantially airtight seal between the calibration tool 150 and theinner surface of the housing 116 such that the microphone 118 is notexposed to ambient noise in addition to the calibrating sound duringcalibration and so that the full measure of the calibrating soundreaches the microphone 118.

In some embodiments, the housing 116 can be configured to have suitablemechanical properties such that the microphone 118 is securely retainedwithin the housing 116, while the housing 116 provides some amount ofattenuation of vibrations caused by movement of the hearing protectiondevice 10 by the wearer, by sound waves from nearby sound sources suchas speakers and/or the environment outside the ear cup 100, and thelike. For example, the housing 116 may be made of rubber or arubber-like material. Furthermore, in some embodiments in which thehousing 116 is a monolithic structure formed as a single piece orcomponent, some benefits of the invention include a reduction in numberand complexity of components required for noise sensing in the hearingprotection device leading to a reduction in manufacturing cost andcomplexity, a reduction in probability of component failure, and areduced occupied volume leading to a smaller possible ear cup 100profile. Also, since the microphone 118 can be calibrated, the accuracyof noise detection will be improved. Furthermore, since the microphone118 can be calibrated without significant disassembly of the ear cup100, the cost, time, and complexity of calibration of the microphone 118are reduced. Furthermore, since the axial bore 123 of the housing 116 isdimensioned and configured to slideably and sealably receive thestandard calibration tool 150 during calibration of the microphone 118,the in situ calibration of the microphone 118 is more effective, meaningthe accuracy of the calibrated microphone 118 for this hearingprotection device 10 is greater than microphones of conventional hearingprotection devices that are not able to be calibrated at all, not ableto be calibrated after assembly of the hearing protection device, and/orcan only be calibrated in less than airtight environments.

In some embodiments, the microphone 118, which can be any suitable typeof microphone such as a microelectro-mechanical systems- (MEMS)-basedmicrophone or the like, can be mounted on, fixed to, electricallycoupled to, soldered to, and/or otherwise coupled to the sensor PCB 114a. In some embodiments, the sensor PCB 114 a can be particularlydimensioned and configured such that a portion of the sensor PCB 114 acan be retained, with the microphone 118, within the noise sensorreceiving portion 125 of the housing 116. In some embodiments, thesensor PCB 114 a can have any suitable form factor such that the sensorPCB 114 a can sealably abut a surface of the noise sensor receivingportion 125 of the housing 116. For instance, the sensor PCB 114 a canhave a form factor that is substantially flat, planar, smooth, round,square, rectangular, quadrilateral, quadrangular, tubular, ellipsoidal,homogenous, even, symmetrical, asymmetrical, or the like. In someembodiments, the sensor PCB 114 a or a portion thereof can be at leastpartially flexible. In some embodiments, the ear cup 100 can furthercomprise a main PCB 114 c electrically connected via a flexible PCB 114b to the sensor PCB 114 a, the sensor PCB 114 a configured to beelectrically coupled to the microphone 118. In some embodiments, themain PCB 114 c may comprise a processor and memory for performing thesignal processing of at least a portion of the hearing protectiondevice, such as the examples described herein.

In some embodiments, the slot of the noise sensor receiving portion 125of the housing 116 can define a volume having extents and dimensionsthat can be substantially inversely similar to the dimensions of thesensor PCB 114 a such that the sensor PCB 114 a can be securely disposedwithin the receiving portion of the housing 116 without adhesive orfasteners or otherwise securing the sensor PCB 114 a within the housingother than by the relative dimensions of either. In some embodiments,the noise sensor receiving portion 125 of the housing 116 can beconfigured and dimensioned to releasably retain the noise sensor,comprising the sensor PCB 114 a and the microphone 118, within the noisesensor receiving portion 125 of the housing 116. In other words, theparticular dimensions of the noise sensor receiving portion 125 of thehousing 116 can be particularly configured to retain the sensorassembly, comprising the sensor PCB 114 a and the microphone 118, withinthe noise sensor receiving portion 125 of the housing 116, therebyforming an airtight seal between at least one of the sensor PCB 114 aand the microphone 118, and the housing 116.

As such, when the noise sensor assembly 110 is properly assembled, airand noise from the environment outside the ear cup 100 can becommunicated into the distal portion of the axial bore 123 of thehousing 116 and to the microphone 118 and/or the sensor PCB 114 a, butis prevented from communicating through the axial bore 123 past themicrophone 118 and/or the sensor PCB 114 a. As such, noise from theenvironment outside the ear cup 100 can be freely measured using thenoise sensor assembly 110 but the interior space of the ear cup 100,including the proximal portion of the axial bore 123 of the housing 116is not substantially exposed to the noise, air, contaminants, and thelike from the environment outside the ear cup 100 due to the airtightseal and noise reduction technologies described herein.

In some embodiments, the exterior casing 117 of the ear cup 100 and theremovable securing collar 111 can comprise or be formed from anysuitably durable yet light material, such as a plastic material likeacrylonitrile butadiene styrene (ABS) or the like. In some embodiments,the internal dust protector 119 can comprise or be formed from anysuitable filtering material, such as Gore filtration material PE 120205and other suitable ingress protection (IP) filter materials. In someembodiments, the internal dust protector 119 can be further configuredto prevent flux of water between the distal portion of the axial bore123 of the housing 116 and the noise sensor assembly disposed in thenoise sensor receiving portion 125 proximate the distal portion of theaxial bore 123 of the housing 116, thus preventing moisture damage tothe sensor PCB 114 a and/or the microphone 118. In some embodiments, thehousing 116 can comprise or be formed from any suitably durable and yetdeformable material, such as a synthetic rubber like ethylene propylenediene monomer (EPDM) rubber and the like. In some embodiments, theexternal dust protector 113 can comprise or be formed from any suitabledust filtering material such as a foam, a mesh, a woven fiber, and thelike.

In some embodiments, the ear cup 100 can further comprise an internalmicrophone 140 configured as a noise sensor to sense noise exposurewithin the inner space of the ear cup 100. For instance, the internalmicrophone 140 can be configured to measure noise from outside the earcup 100 that is communicated into the inner space of the ear cup 100. Assuch, the hearing protection device 10 can be configured such that thenoise sensor assembly 110, the internal microphone 140, other suitablecomputing devices and/or circuitry, or other devices can be caused totransmit and/or store noise exposure data during use of the hearingprotection device 10. In some embodiments, a signal indicative of amagnitude of noise exposure can be transmitted from the microphone 118and/or the internal microphone 140 to the main PCB 114 c or othersuitable computing devices or circuitry, a memory device, or the like.In some embodiments, the magnitude of noise exposure measured by themicrophone 118 can be compared to the magnitude of noise exposuremeasured by the internal microphone 140 to determine the effectivenessof the active and/or passive noise dampening capabilities of the hearingprotection device 10, to identify improper use by the wearer such aswhen an ear cup 100 is not properly fitted against the wearer's headabout the wearer's ears, and to identify when a noise sensor is in needof calibration or is malfunctioning.

Referring now to FIGS. 2A-2E, an ear cup (e.g., 110) for a hearingprotection device (e.g., 10) can include a housing 216 as illustrated,according to an embodiment of the present disclosure. Unless otherwisestated, the features of the housing 216 shown in FIGS. 2A-2E may beincluded in the depicted housing 116 in FIGS. 1B-1C, and vice versa. Asillustrated, the housing 216 can be dimensioned and configured to befixably disposed at or proximate an aperture defined through an externalcasing of the ear cup. The housing 216 can define an axial bore 216 ctherethrough between a proximal end 216 g and a distal end (i.e., 216f). In some embodiments, the housing 116 can have a proximal portion 216b of the axial bore 216 c that is defined in part by a slot 216 r and/orledge 216 k such that the proximal portion 216 b is configured toreceive a microphone (e.g., 118) or other such sensor. In someembodiments, the housing 216 can comprise a distal portion 216 d of theaxial bore 216 c having an inner diameter that is less than the innerdiameter of the proximal portion 216 b. In some embodiments, the ledge216 k can be defined by the portion of the axial bore 216 c at thetransition between the narrower distal portion 216 d and the widerproximal portion 216 b. In some embodiments, the ledge 216 k can beformed as a surface facing the proximal end 216 g of the housing 216 andconfigured to engage the microphone PCB. In some embodiments, theproximal portion 216 b of the axial bore 216 c can have a wider innerdiameter at a transition point 216 s from the distal portion 216 d tothe proximal portion 216 b, the transition point 216 s at least partlydefining the ledge 216 k. In some embodiments, the inner diameter of theproximal portion 216 b can be smaller at one or more points proximal thetransition point 216 s such that the slot 216 r is formed. In someembodiments, the slot 216 r can be the portion of the proximal portion216 b or of the axial bore 216 c in general that has the largest innerdiameter such that the noise sensor can be retained in the slot 216 ragainst movement in an axial direction by a reduced inner diameter bothdistal the slot and proximal the slot 216 r. In some embodiments, anarrower region (e.g., defined by one or more internal surfaces 216 e,216 t) of the proximal portion 216 b of the axial bore 216 c proximalthe slot 216 r can be at least partially open in a radial direction(e.g., a cutout in the side wall of the portion of the axial boreproximal to the slot), meaning, in some embodiments, a region of anouter wall (e.g., 216 a, 216 q, 216 h) of the housing 216 aligned withthe narrower region of the proximal portion 216 b may extend only partof the way around the axial bore 216 c, such that one or more componentsof the noise sensor can extend out radially from the proximal portion216 b of the axial bore 216 c at a location proximal the slot 216 r.

In some embodiments, the distal portion 216 d of the housing 216 can beconfigured to receive ambient noise from the environment outside the earcup and communicate that ambient noise to the microphone or other suchsensor disposed and retained within the proximal portion 216 b (or aportion thereof known herein as a noise sensor receiving portion 216 r)of the housing 216. In some embodiments, the microphone or other suchsensor disposed within the proximal portion of the housing 216 can beconnected to a printed circuit board (PCB, e.g., the PCB 114 a) having asuitable form factor such that at least a portion of the PCB is retainedwithin a noise sensor receiving portion 216 j of the axial bore 216 c ofthe housing 216. In some embodiments, the proximal portion 216 b cancomprise or define the noise sensor receiving portion 216 j. In someembodiments, the noise sensor receiving portion 216 j can be defined asa portion of the axial bore 216 c within the proximal portion 216 b andadjacent the distal portion 216 d. In some embodiments, the one or morePCBs can include a microphone PCB 114 a operably coupled to themicrophone 118 or other such sensor, a flexible PCB 114 b operablyconnected to the microphone PCB 114 a, and a main PCB 114 c to which theflexible PCB 114 b is operably coupled.

In some embodiments, the distal portion 216 d of the axial bore 216 c ofthe housing 216 can be configured and dimensioned such that a noisesensor calibration tool (e.g., 150) can be securely fixed within theaxial bore 216 c for microphone calibration slideably disposing thenoise sensor calibration tool through the distal end of the axial bore216 d and towards the proximal portion 216 b of the housing 216. In someembodiments, securely fixing the noise sensor calibration tool withinthe axial bore 216 c of the housing 216 for calibration of themicrophone or other such noise sensor can help prevent or reduce ambientnoise from the environment outside the ear cup being detected by themicrophone during calibration and can prevent or reduce emission of acalibrating noise emitted by the noise sensor calibration tool during insitu calibration of the microphone or other such noise sensor to outsidethe housing 216, such as to the interior space of the ear cup or theenvironment outside the ear cup. As such, in some embodiments, themicrophone or other such noise sensor can be calibrated in place withoutsignificant disassembly of the hearing protection device and such thatthe space around the microphone is substantially airtight duringcalibration, increasing the accuracy of calibration.

In some embodiments, such as when a hearing protection system andassociated apparatus benefit from being airtight, during use and/orduring calibration, it was found to be helpful to dimension andconfigure the housing 216 to have or define a securing portion 216 n ator near the distal end of the housing 216, the securing portion 216 ncomprising a narrower portion 216 m relative to the outer diameter ofthe main body of the housing 216 proximal the narrower portion of thesecuring portion 216 n and a wider portion 216 f of the securing portion216 n distal the narrower portion 216 m of the securing portion 216 n.In some embodiments, an outer diameter of the narrower portion 216 m ofthe securing portion 216 n can be dimensioned and configured tocorrespond substantially with an inner diameter of the aperture of theexternal casing of the ear cup or one or more intermediate components(e.g., the contacting lip 112) such that the housing 216 can be insertedinto the aperture of the external casing and retained sealably in placewhen an outer surface of the narrower portion 216 m of the securingportion 216 n abuts an inner surface or an inner edge of the aperture ofthe external casing or other intermediate component at the aperture. Insome embodiments, the housing 216 can be at least somewhat deformablesuch that the wider portion 216 f of the securing portion 216 n can befit through the aperture of the external casing of the ear cup duringassembly of the ear cup. In some embodiments, the ear cup can beassembled, at least in part, by temporarily deforming the wider portion216 f of the securing portion 216 n at or near the distal end of thehousing 216 and fitting the distal portion 216 f of the housing 216through the aperture of the external casing of the ear cup from theinside of the ear cup, soldering or otherwise electrically coupling themicrophone to the PCB, and disposing the microphone and a portion of thePCB into the proximal end of the axial bore 216 c of the housing 116until the microphone and/or the portion of the PCB come(s) to rest inthe slot 216 r and/or on the ledge 216 k, the ledge 216 k defined as aninternal surface perpendicular to the axial bore 216 c and positioned ata transition point 216 s where the proximal portion 216 b of the axialbore 216 c of the housing 216 narrows to define a proximal end of thedistal portion 216 d of the axial bore 216 c. In some embodiments, theledge 216 k can comprise a ridge 216 u raised above the surface of theledge 216 k in a proximal direction and configured to sealably engage atleast one of the sensor PCB 114 a and the microphone 118. In someembodiments, the housing 216 can be a monolithic structure in order tofacilitate the airtight nature of the interior region of the ear cupduring use of the hearing protection device and the airtight nature ofthe axial bore of the housing 216 during calibration of the microphone.

In some embodiments, the distal portion 216 d of the axial bore 216 c ofthe housing 216 can be configured to acoustically communicate with anexternal environment via the aperture defined in the external casing ofthe ear cup. In some embodiments, the housing 216 can define a noisesensor receiving portion 216 j comprising the slot 216 r, the ledge 216k and the ridge 216 u, the slot 216 r, the ledge 216 k, and/or the ridge216 u configured to engage the PCB and/or the microphone of the noisesensor assembly. In some embodiments, the slot 216 r and/or the ledge216 k of the housing 216 can be configured to retain the noise sensor,such that the microphone faces the axial bore, e.g., the distal end ofthe axial bore. In some embodiments, in an instance in which the noisesensor is engaged with the housing 216, the noise sensor can be sealedor substantially sealed against the housing 216 and the noise sensor andthe housing 216 can be configured to seal the aperture defined by theexternal casing of the ear cup. In other words, in some embodiments, thehousing 216 can be secured at or proximate the aperture of the externalcasing and the microphone and/or PCB can be secured within the noisesensor receiving portion 216 j of the housing 216 such that ambientnoise from outside the ear cup can reach the microphone by way of thedistal portion 216 d of the axial bore 216 c.

In some embodiments, the distal portion 216 d of the axial bore 216 c ofthe housing 216 can be accessible for in situ calibration of themicrophone either during normal use of the hearing protection device orafter only removing minimal components, such as only the removablesealing collar or only the removable sealing collar and an external dustprotector. In other words, in some embodiments, a calibration toolhaving a sufficient form factor can be slideably inserted into the axialbore 216 c of the housing 216 such that a calibrating sound can beemitted nearby the microphone. In some embodiments, it can be helpful oreven necessary to form an airtight or substantially airtight seal withthe inner surface of the distal portion 216 d of the axial bore 216 csuch that the microphone is not exposed to ambient noise in addition tothe calibrating sound during calibration and so that the full magnitudeof the calibrating sound reaches the microphone.

In some embodiments, the housing 216 can be configured to have suitablemechanical properties such that the microphone is securely retainedwithin the housing 216, but that the housing 216 provides some amount ofattenuation of vibrations caused by movement of the hearing protectiondevice by the wearer, by sound waves from nearby sound sources such asspeakers and/or the environment outside the ear cup, and the like.Furthermore, in some embodiments in which the housing 216 is amonolithic structure formed as a single piece or component, somebenefits of the invention include a reduction in number and complexityof components required for noise sensing in the hearing protectiondevice leading to a reduction in manufacturing cost and complexity, areduction in probability of component failure, and a reduced occupiedvolume leading to a smaller possible ear cup profile. Also, since themicrophone can be calibrated, the accuracy of noise detection will beimproved. Furthermore, since the microphone can be calibrated withoutsignificant disassembly of the ear cup, the cost, time, and complexityof calibration of the microphone are reduced. Furthermore, since theaxial bore of the housing 216 is dimensioned and configured to slideablyand sealably receive standard calibration tools during calibration ofthe microphone, the in situ calibration of the microphone is moreeffective, meaning the accuracy of the calibrated microphone for thishearing protection device is greater than microphones of conventionalhearing protection devices that are not able to be calibrated at all,not able to be calibrated after assembly of the hearing protectiondevice, and/or can only be calibrated in less than airtightenvironments.

In some embodiments, the housing 216 comprises a rounded exteriorsurface 216 q, one or more flat exterior surfaces 216 a, 216 h on theoutside of the housing 216 oriented parallel to the axial bore 216 c,and one or more other flat exterior surfaces 216 g, 216 p, 216 i on theoutside of the housing 216 oriented perpendicular to the axial bore 216c. In some embodiments, the rounded exterior surface 216 q and/or theone or more flat exterior surfaces 216 a, 216 h may be configured toabut a portion or component of the ear cup. In some embodiments, therounded exterior surface 216 q and/or the one or more flat exteriorsurfaces 216 a, 216 h may be configured to abut a portion or componentof the ear cup such that the housing 216 is prevented from rotationrelative to an orientation of the rest of the ear cup. In someembodiments, the proximal portion 216 b of the axial bore 216 c of thehousing 216 may comprise or be adjoining one or more flat interiorsurfaces 216 e such that a cut-out is defined between the one or moreflat interior surfaces 216 e and through a portion of a flat exteriorsurface 216 h or a rounded exterior surface 216 q. In some embodiments,the PCB may be disposed within the noise sensor receiving portion 216 jof the housing 216 along with the microphone, while another portion ofthe PCB extends from the axial bore 216 c, through the cut-out portionof the flat exterior surface 216 h or the rounded exterior surface 216 qof the housing 216, and into the interior space of the ear cup such thatthe PCB can be electrically coupled to other electronic components suchas another PCB, a microprocessor or the like. In some embodiments, theportions of the housing surrounding the cut-out may define a horseshoeshape to facilitate insertion of the PCB by separating or pulling apartthe distal ends of the horseshoe shape (e.g., with pliers) to allow themicrophone PCB to insert into the slot.

Referring now to FIGS. 3A-3D, a noise sensor assembly 210 can compriseat least a microphone 218 and a sensor printed circuit board (PCB) 214a. In some embodiments, the sensor PCB 214 a can be electrically and/oroperably coupled to the microphone 218. In some embodiments, the sensorPCB 214 a can be electrically and/or operably coupled to a flexible PCB214 b and the flexible PCB 214 b can be operably coupled to a main PCB214 c. In some embodiments, the noise sensor assembly 210 or a portionthereof can be disposed within a portion of the housing 216, such as thenoise sensor receiving portion 216 j. In some embodiments, themicrophone 218 can be any suitable type of microphone such as amicroelectro-mechanical systems- (MEMS)-based microphone or the like,can be mounted on, fixed to, electrically coupled to, soldered to,and/or otherwise coupled to the sensor PCB 214 a. In some embodiments,the sensor PCB 214 a can be particularly dimensioned and configured suchthat at least a portion of the sensor PCB 214 a can be retained, withthe microphone 218, within the noise sensor receiving portion 216 j ofthe housing 216. In some embodiments, the sensor PCB 214 a can have anysuitable form factor such that the sensor PCB 214 a can sealably abut asurface of the receiving portion of the housing 216. For instance, thesensor PCB 214 a can have a form factor that is substantially flat,planar, smooth, round, square, rectangular, quadrilateral, quadrangular,tubular, ellipsoidal, homogenous, even, symmetrical, asymmetrical, orthe like. In the embodiment depicted in FIGS. 3A-3B, the sensor PCB 214a forms a substantially circular shape corresponding to the shape of theslot 216 r shown in FIG. 2A-2E. In some embodiments, the electricalcomponents mounted to the sensor PCB 214 a may be offset from the edgessuch that the housing 216 can grip the sensor PCB 214 a.

In some embodiments, the noise sensor receiving portion 216 j of thehousing 216 can define a volume having extents and dimensions that canbe substantially inversely similar to the dimensions of the sensor PCB214 a such that at least a portion of the sensor PCB 214 a can besecurely disposed within the receiving portion of the housing 216without adhesive or fasteners or otherwise securing the sensor PCB 214 awithin the housing 214 other than by the relative dimensions of either.In some embodiments, the noise sensor receiving portion 216 j of thehousing 216 can be configured and dimensioned to releasably retain thenoise sensor, comprising the sensor PCB 214 a and the microphone 218,within the noise sensor receiving portion 216 j of the housing 216 in asimilar manner. In other words, the particular dimensions of the noisesensor receiving portion 216 j of the housing 216 can be particularlyconfigured to retain the sensor assembly, comprising the sensor PCB 214a and the microphone 218, within the noise sensor receiving portion 216j of the housing 216, thereby forming an airtight seal between at leastone of the sensor PCB 214 a and the microphone 218, and the housing 218.

In some embodiments, the sensor PCB 214 a can have any suitable formfactor such that the sensor PCB 214 a can sealably abut a surface of thereceiving portion of the housing 216. In some embodiments, the sensorPCB 214 a, the flexible PCB 214 b and/or the main PCB 214 c can have aform factor that is substantially flat, planar, smooth, round, square,rectangular, quadrilateral, quadrangular, tubular, ellipsoidal,homogenous, even, symmetrical, asymmetrical, or the like. In someembodiments, the sensor PCB 214 a or a portion thereof can be at leastpartially flexible. In some embodiments, the sensor PCB 214 a can beelectrically connected via the flexible PCB 216 b to the main PCB 214 cor other such computing device or circuitry, and the sensor PCB 214 acan be electrically connected to the microphone 218.

As such, when the noise sensor assembly 210 is properly assembled, airand noise from the environment outside the ear cup can be communicatedinto the distal portion 216 d of the axial bore 216 c of the housing 216and to the microphone 218 and/or the sensor PCB 214 a, but is preventedfrom communicating through the axial bore 216 c to locations proximalthe microphone 218 and/or the sensor PCB 214 a. As such, noise from theenvironment outside the ear cup can be freely measured using the noisesensor assembly 210 but the interior space of the ear cup, including theproximal portion 216 b of the axial bore 216 c of the housing 216 issubstantially not exposed to the noise, air, contaminants, and the likefrom the environment outside the ear cup based upon the air tightnessand noise reduction techniques described herein.

In some embodiments, the microphone 218 can comprise a silicon waferhaving a movable membrane and a fixed back plate over a cavity in thebase wafer. In some embodiments, the sensor back plate can have a stiffperforated structure. In some embodiments, the microphone 218 can be amicroelectro-mechanical system (MEMS) microphone. Without wishing to bebound by any particular theory, in response to air movements related tonoise exposure, the movable membrane of the microphone 218 can move,causing a change in a magnitude of a capacitance between the movablemembrane and the fixed back plate, which can be converted by anysuitable ASIC to an electrical signal. For instance, the ASIC can use acharge pump to place a fixed charge on the movable membrane of themicrophone 218, and the ASIC can then measure voltage variations causedby capacitance changes related to movements of the movable membranerelative to the fixed back plate. While the microphone 218 can comprisethe above-mentioned components according to some embodiments, themicrophone 218 can comprise any suitable combination of components suchthat noise exposure can be sensed.

In some embodiments, the sensor PCB 214 a and/or the flexible PCB 214 bcan comprise an insulated substrate supporting a plurality of electricalcomponents and conductive tracks, and can be configured to communicateelectrical signals and data between computing devices and other relatedcircuitry. In some embodiments, the sensor PCB 214 a can be configuredto receive the electrical signal from the microphone 218, for examplefrom the ASIC, the electrical signal indicative of the movement of themovable membrane of the microphone 218 in response to a magnitude of airmovements related to a magnitude of noise exposure. While the sensor PCB214 a can comprise the above-mentioned components according to someembodiments, the sensor PCB 214 a can comprise any suitable combinationof components such that a signal received from the microphone 218 can betransmitted and/or interpreted relative to a magnitude of noise exposuresensed by the microphone 218.

To provide an overall understanding, certain illustrative embodimentshave been described; however, it will be understood by one of ordinaryskill in the art that the systems, apparatuses, and methods describedherein can be adapted and modified to provide systems, apparatuses, andmethods for other suitable applications and that other additions andmodifications can be made without departing from the scope of thesystems, apparatuses, and methods described herein.

The embodiments described herein have been particularly shown anddescribed, but it will be understood that various changes in form anddetails may be made. Unless otherwise specified, the illustratedembodiments can be understood as providing exemplary features of varyingdetail of certain embodiments, and therefore, unless otherwisespecified, features, components, modules, and/or aspects of theillustrations can be otherwise combined, separated, interchanged, and/orrearranged without departing from the disclosed systems or methods.Additionally, the shapes and sizes of components are also exemplary andunless otherwise specified, can be altered without affecting the scopeof the disclosed and exemplary systems, apparatuses, or methods of thepresent disclosure.

Conventional terms in the field of electrochemical cells have been usedherein. The terms are known in the art and are provided only as anon-limiting example for convenience purposes. Accordingly, theinterpretation of the corresponding terms in the claims, unless statedotherwise, is not limited to any particular definition. Thus, the termsused in the claims should be given their broadest reasonableinterpretation.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement that is adapted to achieve the same purpose may besubstituted for the specific embodiments shown. Many adaptations will beapparent to those of ordinary skill in the art. Accordingly, thisapplication is intended to cover any adaptations or variations.

The above detailed description includes references to the accompanyingdrawings, which form a part of the detailed description. The drawingsshow, by way of illustration, specific embodiments that may bepracticed. These embodiments are also referred to herein as “examples.”Such examples may include elements in addition to those shown ordescribed. However, the present inventors also contemplate examples inwhich only those elements shown or described are provided. Moreover, thepresent inventors also contemplate examples using any combination orpermutation of those elements shown or described (or one or more aspectsthereof), either with respect to a particular example (or one or moreaspects thereof), or with respect to other examples (or one or moreaspects thereof) shown or described herein.

All publications, patents, and patent documents referred to in thisdocument are incorporated by reference herein in their entirety, asthough individually incorporated by reference. In the event ofinconsistent usages between this document and those documents soincorporated by reference, the usage in the incorporated reference(s)should be considered supplementary to that of this document; forirreconcilable inconsistencies, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patentdocuments, to include one or more than one, independent of any otherinstances or usages of “at least one” or “one or more.” In thisdocument, the term “or” is used to refer to a nonexclusive or, such that“A or B” includes “A but not B,” “B but not A,” and “A and B,” unlessotherwise indicated. In this document, the terms “including” and “inwhich” are used as the plain-English equivalents of the respective terms“comprising” and “wherein.” Also, in the following claims, the terms“including” and “comprising” are open-ended, that is, a system, device,article, or process that includes elements in addition to those listedafter such a term in a claim are still deemed to fall within the scopeof that claim. Moreover, in the following claims, the terms “first,”“second,” and “third,” etc. are used merely as labels, and are notintended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and notrestrictive. For example, the above-described examples (or one or moreaspects thereof) may be used in combination with each other. Otherembodiments may be used, such as by one of ordinary skill in the artupon reviewing the above description. The Abstract is provided to complywith 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain thenature of the technical disclosure and is submitted with theunderstanding that it will not be used to interpret or limit the scopeor meaning of the claims.

In this Detailed Description, various features may have been groupedtogether to streamline the disclosure. This should not be interpreted asintending that an unclaimed disclosed feature is essential to any claim.Rather, inventive subject matter may lie in less than all features of aparticular disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description, with each claim standing onits own as a separate embodiment, and it is contemplated that suchembodiments may be combined with each other in various combinations orpermutations. The scope of the embodiments should be determined withreference to the appended claims, along with the full scope ofequivalents to which such claims are entitled.

1. A noise sensor assembly for a hearing protection device, the noise sensor assembly comprising: a noise sensor comprising a microphone electrically coupled to a printed circuit board (PCB); and a housing dimensioned and configured to be fixably disposed at or proximate an aperture defined in an outer surface of an external casing of the hearing protection device, wherein the housing comprises an inner surface defining an axial bore, wherein a distal end of the axial bore is configured to acoustically communicate with an external environment via the aperture, wherein the housing defines a noise sensor receiving portion comprising a slot configured to engage the PCB of the noise sensor, wherein the slot of the housing is configured to retain the noise sensor, such that the microphone faces the axial bore, and wherein, in an instance in which the noise sensor is engaged with the housing, the noise sensor is sealed against the housing.
 2. The noise sensor assembly of claim 1, wherein the axial bore of the housing is dimensioned and configured to slideably receive a calibration tool to form an airtight seal with the inner surface of the housing.
 3. The noise sensor assembly of claim 1, wherein the housing further defines a securing portion at a distal end, the securing portion adapted to contact and secure the housing with respect to a portion of the outer surface of the hearing protection device.
 4. The noise sensor assembly of claim 1, further comprising: an internal dust protector disposed between the noise sensor receiving portion of the housing and the noise sensor, and wherein the internal dust protector is disposed between the microphone and the axial bore.
 5. The noise sensor assembly of claim 1, wherein the housing comprises at least one of a vibration attenuation material and a noise dampening material.
 6. The noise sensor assembly of claim 1, wherein, in an instance in which the noise sensor is engaged with the housing, the noise sensor is retained within the noise sensor receiving portion and abuts the slot.
 7. An ear cup for a hearing protection device, the ear cup comprising: an external casing defining an aperture; and a noise sensor comprising a microphone electrically coupled to a printed circuit board (PCB) and a housing fixably disposed at or proximate the aperture defined by the external casing, wherein the housing comprises an inner surface defining an axial bore, wherein a distal end of the axial bore is configured to acoustically communicate with an external environment via the aperture, wherein the housing defines a noise sensor receiving portion comprising a slot configured to engage the PCB of the noise sensor, wherein the slot of the housing is configured to retain the noise sensor, such that the microphone faces the axial bore, and wherein, in an instance in which the noise sensor is engaged with the housing, the noise sensor is sealed against the housing, and the noise sensor and the housing seal the aperture defined by the external casing.
 8. The ear cup of claim 7, further comprising: a removable securing collar, wherein the external casing comprises a first portion and a second portion, the second portion defining the aperture configured to sealably retain the removable securing collar, the second portion configured to sealingly engage the first portion such that the first portion, the second portion, and the removable securing collar seal the aperture in the external casing.
 9. The ear cup of claim 7, wherein the noise sensor receiving portion of the axial bore has a first inner diameter and the distal end portion of the axial bore has a second inner diameter less than the first inner diameter.
 10. The ear cup of claim 7, further comprising a removable sealing collar configured to sealably retain the housing at or proximate the aperture defined by the external casing, the removable securing collar comprising an opening such that the distal end of the axial bore of the housing is configured to acoustically communicate with the external environment via the aperture of the external casing and the opening of the removable sealing collar.
 11. The ear cup of claim 7 further comprising a removable sealing collar configured to be retained by the aperture, wherein the axial bore of the housing is configured such that when the removable securing collar is removed and the calibration tool is slideably inserted into the axial bore of the housing, the calibration tool forms an airtight seal with an inner surface of the axial bore of the housing.
 12. The ear cup of claim 7, further comprising: an external dust protector disposed between the housing and the removable securing collar.
 13. The ear cup of claim 7, wherein the housing further comprises a securing portion disposed about the axial bore, the securing portion comprising a first securing portion at a distal end of the housing having a first outer diameter and a second securing portion proximal of the first securing portion, the second securing portion have a second outer diameter less than the first outer diameter, the first securing portion and the second securing portion defining a flange and recess configured to secure the housing relative to the external casing.
 14. The ear cup of claim 13, wherein, in an instance in which the noise sensor is engaged with the housing and the housing is sealably disposed directly or indirectly at or proximate the aperture of the external casing of the ear cup, and the ear cup is sealably engaged to a wearer's head about the wearer's ear, an internal volume of the ear cup is substantially airtight.
 15. A method for calibrating the noise sensor of the hearing protection device of claim 1, the method comprising: disposing a calibration tool through the aperture via the axial bore of the housing such that an interior of the calibration tool and the microphone are part of a closed system; emitting, by the calibration tool, a calibrating sound having predetermined sound characteristics; receiving, using the microphone, one or more detected sound characteristics of the calibrating sound; and in an instance in which a comparison of the one or more detected sound characteristics of the calibrating sound received by the microphone and the sound characteristics of the calibrating sound is indicative of a calibration error, calibrating the noise sensor relative to the calibrating sound. 